Article Of Footwear Incorporating A Knitted Component

ABSTRACT

An article of footwear has an upper and a sole structure secured to the upper. The upper includes a knitted component and, in some configurations, a skin layer secured to the knitted component. The knitted component may have a plurality of protruding areas that extend outward and away from a void within the upper for receiving a foot of a wearer. The protruding areas may include one or both of (a) a first tubular structure and an inlaid strand extending through the first tubular structure and (b) a second tubular structure and yarn sections extending across the second tubular structure.

CROSS-REFERENCE TO RELATED APPLICATION

This non-provisional patent application is a continuation of and claimspriority to U.S. Provisional Patent Application Ser. No. 61/727,010(Attorney Docket No. 51-2906), which was filed in the U.S. Patent andTrademark Office on 15 Nov. 2012 and entitled Article Of FootwearIncorporating A Knitted Component, the disclosure of which is entirelyincorporated herein by reference.

BACKGROUND

Conventional articles of footwear generally include two primaryelements, an upper and a sole structure. The upper is secured to thesole structure and forms a void on the interior of the footwear forcomfortably and securely receiving a foot. The sole structure is securedto a lower surface of the upper so as to be positioned between the upperand the ground. In some articles of athletic footwear, for example, thesole structure may include a midsole and an outsole. The midsole may beformed from a polymer foam material that attenuates ground reactionforces to lessen stresses upon the foot and leg during walking, running,and other ambulatory activities. The outsole is secured to a lowersurface of the midsole and forms a ground-engaging portion of the solestructure that is formed from a durable and wear-resistant material. Thesole structure may also include a sockliner positioned within the voidand proximal a lower surface of the foot to enhance footwear comfort.

The upper generally extends over the instep and toe areas of the foot,along the medial and lateral sides of the foot, and around the heel areaof the foot. In some articles of footwear, such as basketball footwearand boots, the upper may extend upward and around the ankle to providesupport or protection for the ankle. Access to the void on the interiorof the upper is generally provided by an ankle opening in a heel regionof the footwear. A lacing system is often incorporated into the upper toadjust the fit of the upper, thereby permitting entry and removal of thefoot from the void within the upper. The lacing system also permits thewearer to modify certain dimensions of the upper, particularly girth, toaccommodate feet with varying dimensions. In addition, the upper mayinclude a tongue that extends under the lacing system to enhanceadjustability of the footwear, and the upper may incorporate a heelcounter to limit movement of the heel.

Various materials are conventionally utilized in manufacturing theupper. The upper of athletic footwear, for example, may be formed frommultiple material elements. The materials may be selected based uponvarious properties, including stretch-resistance, wear-resistance,flexibility, air-permeability, compressibility, and moisture-wicking,for example. With regard to an exterior of the upper, the toe area andthe heel area may be formed of leather, synthetic leather, or a rubbermaterial to impart a relatively high degree of wear-resistance. Leather,synthetic leather, and rubber materials may not exhibit the desireddegree of flexibility and air-permeability for various other areas ofthe exterior. Accordingly, the other areas of the exterior may be formedfrom a synthetic textile, for example. The exterior of the upper may beformed, therefore, from numerous material elements that each impartdifferent properties to the upper. An intermediate or central layer ofthe upper may be formed from a lightweight polymer foam material thatprovides cushioning and enhances comfort. Similarly, an interior of theupper may be formed of a comfortable and moisture-wicking textile thatremoves perspiration from the area immediately surrounding the foot. Thevarious material elements and other components may be joined with anadhesive or stitching. Accordingly, the conventional upper is formedfrom various material elements that each impart different properties tovarious areas of the footwear.

SUMMARY

An article of footwear has an upper and a sole structure secured to theupper. In various configurations, the upper includes a knitted componenthaving a plurality of protruding areas that extend outward and away froma void within the upper for receiving a foot of a wearer. The protrudingareas include one or both of (a) a first tubular structure and an inlaidstrand extending through the first tubular structure and (b) a secondtubular structure and yarn sections extending across the second tubularstructure. In addition, a skin layer may be secured to the knittedcomponent.

A method for manufacturing an upper for an article of footwear mayinclude positioning a skin layer adjacent to a knitted component and inan overlapping configuration, the knitted component having regions withdifferent thicknesses. The skin layer and the knitted component may belocated between a first surface and a second surface of a press. Thefirst surface includes a first material, and the second surface includesa second material, the first material having greater compressibilitythan the second material. In addition, the skin layer and the knittedcomponent may be compressed between the first surface and the secondsurface to join the skin layer to the knitted component.

An article of footwear has an upper and a sole structure secured to theupper. In various configurations, the upper includes a foot region andan ankle region. The foot region covers at least a portion of a foot ofa wearer and includes a foot part of a knitted component. The ankleregion covers at least a portion of an ankle of the wearer and includesan ankle part of the knitted component. The foot part and the ankle partof the knitted component are formed from unitary knit construction. Thefoot region has a first degree of stretch and the ankle region has asecond degree of stretch, with the first degree of stretch being lessthan the second degree of stretch.

An article of footwear has an upper and a sole structure secured to theupper. In various configurations, the upper includes a knitted componentextending through a throat area of the upper. The knitted componentdefines a channel in the throat area, with the channel including twooverlapping knit layers formed of unitary knit construction. The upperalso includes a plurality of lace-receiving elements located on oppositesides of the throat area, two of the lace-receiving elements are locatedadjacent to opposite ends of the channel. A lace extends through thechannel and engages the lace-receiving elements.

The advantages and features of novelty characterizing aspects of theinvention are pointed out with particularity in the appended claims. Togain an improved understanding of the advantages and features ofnovelty, however, reference may be made to the following descriptivematter and accompanying figures that describe and illustrate variousconfigurations and concepts related to the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a lateral side elevational view of a first configuration of anarticle of footwear.

FIG. 2 is a medial side elevational view of the first configuration ofthe article of footwear.

FIG. 3 is a top plan view of the first configuration of the article offootwear.

FIGS. 4A-4C are cross-sectional views of the first configuration of thearticle of footwear, as respectively defined by section lines 4A-4C inFIG. 3.

FIG. 5 is a top plan view of a knitted component and a skin layer froman upper of the first configuration of the article of footwear.

FIG. 6 is an exploded top plan view of the knitted component and theskin layer.

FIGS. 7A-7C are cross-sectional views of the knitted component and theskin layer, as respectively defined by section lines 7A-7C in FIG. 5.

FIGS. 8A and 8B are perspective views of an exemplary portion of theknitted component and the skin layer.

FIGS. 9A-9C are top plan views depicting further configurations of theknitted component.

FIGS. 10A-10D are perspective views of a process for utilizing a pressto bond the knitted component and the skin layer.

FIGS. 11A-11D are cross-sectional views of the process for utilizing thepress, as respectively defined by section lines 11A-11D in FIGS.10A-10D.

FIG. 12 is a lateral side elevational view of a second configuration ofthe article of footwear.

FIG. 13 is a medial side elevational view of the second configuration ofthe article of footwear.

FIG. 14 is a top plan view of the second configuration of the article offootwear.

FIG. 15 is a cross-sectional view of the second configuration of thearticle of footwear, as defined by section line 15 in FIG. 14.

FIG. 16 is a top plan view of a third configuration of the article offootwear.

FIG. 17 is a cross-sectional view of the third configuration of thearticle of footwear, as defined by section line 17 in FIG. 16.

FIG. 18 is a top plan view of a tongue from the third configuration ofthe article of footwear.

FIG. 19 is a cross-sectional view of the tongue, as defined by sectionline 19 in FIG. 18.

FIGS. 20 and 21 are top plan views of further configurations of theknitted component and a lace.

FIG. 22 is a cross-sectional view, as defined by section line 22 in FIG.21.

FIG. 23 is a bottom plan view of a configuration of the knittedcomponent that includes an interior layer.

FIG. 24 is a cross-sectional view of the article of footwearcorresponding with FIG. 4A and depicting the interior layer.

FIGS. 25A and 25B are top plan views corresponding with FIG. 5 anddepicting further configurations for the skin layer from an upper of thefirst configuration of the article of footwear.

DETAILED DESCRIPTION

The following discussion and accompanying figures disclose an article offootwear having an upper that includes a knitted component and a skinlayer. The article of footwear is disclosed as having a generalconfiguration suitable for walking or running. Concepts associated withthe footwear, including the upper, may also be applied to a variety ofother athletic footwear types, including baseball shoes, basketballshoes, cross-training shoes, cycling shoes, football shoes, soccershoes, sprinting shoes, tennis shoes, and hiking boots, for example. Theconcepts may also be applied to footwear types that are generallyconsidered to be non-athletic, including dress shoes, loafers, sandals,and work boots. The concepts disclosed herein apply, therefore, to awide variety of footwear types.

General Footwear Structure

An article of footwear 100 is depicted in FIGS. 1-4C as including a solestructure 110 and an upper 120. Whereas sole structure 110 is locatedunder and supports a foot of a wearer, upper 120 provides a comfortableand secure covering for the foot. As such, the foot may be locatedwithin a void in upper 120 to effectively secure the foot withinfootwear 100 or otherwise unite the foot and footwear 100. Moreover,sole structure 110 is secured to a lower area of upper 120 and extendsbetween the foot and the ground to attenuate ground reaction forces(i.e., cushion the foot), provide traction, enhance stability, andinfluence the motions of the foot, for example.

For reference purposes, footwear 100 may be divided into three generalregions: a forefoot region 101, a midfoot region 102, and a heel region103. Forefoot region 101 generally encompasses portions of footwear 100corresponding with forward portions of the foot, including the toes andjoints connecting the metatarsals with the phalanges. Midfoot region 102generally encompasses portions of footwear 100 corresponding with middleportions of the foot, including an arch area. Heel region 103 generallyencompasses portions of footwear 100 corresponding with rear portions ofthe foot, including the heel and calcaneus bone. Footwear 100 alsoincludes a lateral side 104 and a medial side 105, which extend througheach of regions 101-103 and correspond with opposite sides of footwear100. More particularly, lateral side 104 corresponds with an outsidearea of the foot (i.e. the surface that faces away from the other foot),and medial side 105 corresponds with an inside area of the foot (i.e.,the surface that faces toward the other foot). Regions 101-103 and sides104-105 are not intended to demarcate precise areas of footwear 100.Rather, regions 101-103 and sides 104-105 are intended to representgeneral areas of footwear 100 to aid in the following discussion. Inaddition to footwear 100, regions 101-103 and sides 104-105 may also beapplied to sole structure 110, upper 120, and individual elementsthereof.

The primary elements of sole structure 110 are a midsole 111, an outsole112, and a sockliner 113. Midsole 111 is secured to a lower surface ofupper 120 and may be formed from a compressible polymer foam element(e.g., a polyurethane or ethylvinylacetate foam) that attenuates groundreaction forces (i.e., provides cushioning) when compressed between thefoot and the ground during walking, running, or other ambulatoryactivities. In further configurations, midsole 111 may incorporateplates, moderators, fluid-filled chambers, lasting elements, or motioncontrol members that further attenuate forces, enhance stability, orinfluence the motions of the foot, or midsole 21 may be primarily formedfrom a fluid-filled chamber. Outsole 112 is secured to a lower surfaceof midsole 111 and may be formed from a wear-resistant rubber materialthat is textured to impart traction. Sockliner 113 is located within thevoid in upper 120 and is positioned to extend under a lower surface ofthe foot to enhance the comfort of footwear 100. Although thisconfiguration for sole structure 110 provides an example of a solestructure that may be used in connection with upper 120, a variety ofother conventional or nonconventional configurations for sole structure110 may also be utilized. Accordingly, the features of sole structure110 or any sole structure utilized with upper 120 may vary considerably.

Upper 120 includes an exterior surface 121 and an opposite interiorsurface 122. Whereas exterior surface 121 faces outward and away fromfootwear 100, interior surface 122 faces inward and defines a majorityor a relatively large portion of the void within footwear 100 forreceiving the foot. The void is shaped to accommodate the foot. When thefoot is located within the void, therefore, upper 120 extends along alateral side of the foot, along a medial side of the foot, over thefoot, around the heel, and under the foot. Moreover, interior surface121 may lay against the foot or a sock covering the foot. Upper 120 alsoincludes a collar 123 that is primarily located in heel region 103 andforms an opening that provides the foot with access to the void. Moreparticularly, the foot may be inserted into upper 120 through theopening formed by collar 123, and the foot may be withdrawn from upper120 through the opening formed by collar 123.

A throat area 124 of upper 120 is located forward of collar 123 andprimarily in midfoot region 102. Although the extent of throat area 124may vary, throat area 124 corresponds with an instep region or uppersurface of the foot and includes a lace 125, a plurality oflace-receiving elements 126, and a tongue 127. Lace 125 engages thevarious lace-receiving elements 126 and follows a zigzagging pathbetween lace-receiving elements 126. Moreover, lace 125repeatedly-passes across throat area 124 and between opposite sides ofthroat area 124. When using footwear 100, lace 125 permits the wearer tomodify dimensions of upper 120 to accommodate the proportions of thefoot. More particularly, lace 125 may be manipulated in a conventionalmanner to permit the wearer to (a) tighten upper 120 around the foot and(b) loosen upper 120 to facilitate insertion and withdrawal of the footfrom the void in upper 120 (i.e., through the opening formed by collar123). Although lace-receiving elements 126 are depicted as apertures inupper 120, and with lace 125 passing through the apertures,lace-receiving elements 126 may be loops, eyelets, hooks, or D-rings.

A majority of upper 120 is formed from a knitted component 130 and askin layer 140, which are depicted separate from a remainder of footwear100 in FIGS. 5 and 6. Knitted component 130 may, for example, bemanufactured through a flat knitting process and extends through each ofregions 101-103, along both lateral side 104 and medial side 105, overforefoot region 101, and around heel region 103. Although portions ofknitted component 130 form exterior surface 121, knitted component 130forms a majority or a relatively large portion of interior surface 122,thereby defining a portion of the void within upper 120. In someconfigurations, knitted component 130 may also extend under the foot.For purposes of example in various figures, however, a strobel sock 128is secured to knitted component 130 and forms a majority of the portionof upper 120 that extends under the foot. In this configuration,sockliner 113 extends over strobel sock 128 and forms a surface uponwhich the foot rests. In addition, a seam 129 extends vertically throughheel region 103, as depicted in FIGS. 3 and 4C, to join edges of knittedcomponent 130.

Skin layer 140 lays adjacent to knitted component 130 and is secured toan exterior of knitted component 130, thereby forming a majority or arelatively large portion of exterior surface 121. Various materials maybe utilized to form skin layer 140, including a polymer sheet, elementsof leather or synthetic leather, a woven or non-woven textile, or ametal foil. As with knitted component 130, skin layer 140 extendsthrough each of regions 101-103, along both lateral side 104 and medialside 105, over forefoot region 101, and around heel region 103. Skinlayer 140 is depicted as being absent from portions of throat area 124(e.g., tongue 127) and interior surface 122. In further configurationsof footwear 100, skin layer 140 may be absent from other areas of upper120 or may extend over portions of throat area 124 and into interiorsurface 122.

The combination of knitted component 130 and skin layer 140 providesvarious advantages to footwear 100. As an example, knitted component 130and skin layer 140 impart a relatively tight and glove-like fit to upper120 that secures the foot within footwear 100 during walking, running,and other ambulatory activities. When formed as a soccer shoe, forexample, the relatively tight and glove-like fit may provide the wearerwith enhanced feel and control of a ball. Skin layer 140 may also beutilized to reinforce areas of upper 120. For example, skin layer 140may inhibit stretch in knitted component 130 and may enhance thewear-resistance or abrasion-resistance of upper 120. Skin layer 140 mayalso impart water-resistance to footwear 100. Additionally, formingfootwear 100 in this configuration may provide a relatively light weightor mass, support for the foot, uniform fit and conformance to a shape ofthe foot, and a relatively seamless interior with enhanced comfort forthe wearer.

The discussion above presents various features and elements of upper120. In further configurations of footwear 100, however, upper 120 mayalso include one or more of (a) a heel counter in heel region 103 forenhancing stability, (b) a toe guard in forefoot region 101 that isformed of a wear-resistant material, and (c) logos, trademarks, andplacards with care instructions and material information. Accordingly,upper 120 may incorporate a variety of other features and elements, inaddition to the features and elements discussed herein and shown in thefigures.

Knitted Component Configuration

Knitted component 130 extends throughout upper 120 and forms a majorityof interior surface 122, thereby defining a portion of the void withinupper 120. Although seams may be present in knitted component 130, amajority of knitted component 130 has a substantially seamlessconfiguration. Moreover, knitted component 130 may be formed of unitaryknit construction. As utilized herein, a knitted component (e.g.,knitted component 130) is defined as being formed of “unitary knitconstruction” when formed as a one-piece element through a knittingprocess. That is, the knitting process substantially forms the variousfeatures and structures of knitted component 130 without the need forsignificant additional manufacturing steps or processes. Althoughportions of knitted component 130 may be joined to each other (e.g.,edges of knitted component 130 being joined together, as at seam 129)following the knitting process, knitted component 130 remains formed ofunitary knit construction because it is formed as a one-piece knitelement. Moreover, knitted component 130 remains formed of unitary knitconstruction when other elements (e.g., lace 125, strobel sock 127logos, trademarks, placards) are added following the knitting process.Examples of various configurations of knitted components that may beutilized for knitted component 130 are disclosed in U.S. Pat. No.6,931,762 to Dua; U.S. Pat. No. 7,347,011 to Dua, et al.; U.S. PatentApplication Publication 2008/0110048 to Dua, et al.; U.S. PatentApplication Publication 2010/0154256 to Dua; and U.S. Patent ApplicationPublication 20120233882 to Huffa, et al., each of which are entirelyincorporated herein by reference.

The primary elements of knitted component 130 are a knit element 131 andan inlaid strand 132. Knit element 131 is formed from at least one yarnthat is manipulated (e.g., with a knitting machine) to form a pluralityof intermeshed loops that define a variety of courses and wales. Thatis, knit element 131 has the structure of a knit textile. Inlaid strand132 extends through knit element 131 and passes between the variousloops within knit element 131. Although inlaid strand 132 generallyextends along courses within knit element 131, inlaid strand 132 mayalso extend along wales within knit element 131. Advantages of inlaidstrand 132 include providing support, stability, and structure. Forexample, inlaid strand 132 assists with securing upper 120 around thefoot, limits deformation in areas of upper 120 (e.g., impartsstretch-resistance), and operates in connection with lace 125 to enhancethe fit of footwear 100. U.S. Patent Application Publication 20120233882to Huffa, et al., which was referenced above and incorporated herein,provides discussion of the manner in which knitted component 130 may beformed, including the process of inlaying or otherwise locating inlaidstrand 132 within knit element 131.

Knit element 131 may incorporate various types and combinations ofstitches and yarns. With regard to stitches, the yarn forming knitelement 131 may have one type of stitch in one area of knit element 131and another type of stitch in another area of knit element 131.Depending upon the types and combinations of stitches utilized, areas ofknit element 131 may have a plain knit structure, a mesh knit structure,or a rib knit structure, for example. The different types of stitchesmay affect the physical properties of knit element 131, includingaesthetics, stretch, thickness, air permeability, andabrasion-resistance of knit element 131. That is, the different types ofstitches may impart different properties to different areas of knittedcomponent 130. With regard to yarns, knit element 131 may have one typeof yarn in one area of knit element 131 and another type of yarn inanother area of knit element 131. Depending upon various designcriteria, knit element 131 may incorporate yarns with different deniers,materials (e.g., cotton, elastane, polyester, rayon, wool, and nylon),and degrees of twist, for example. The different types of yarns mayaffect the physical properties of knit element 131, includingaesthetics, stretch, thickness, air permeability, andabrasion-resistance of knit element 131. That is, the different types ofyarns may impart different properties to different areas of knittedcomponent 130. By combining various types and combinations of stitchesand yarns, each area of knit element 131 may have specific propertiesthat enhance the comfort, durability, and performance of footwear 100.In some configurations, multiple yarns with different colors may beutilized to form knitted component 130. When yarns with different colorsare twisted together and then knitted, knitted component 130 may have aheathered appearance with multiple colors randomly distributedthroughout upper 120.

One or more of the yarns within knit element 131 may be partially formedfrom a thermoplastic polymer material, which softens or melts whenheated and returns to a solid state when cooled. More particularly, thethermoplastic polymer material transitions from a solid state to asoftened or liquid state when subjected to sufficient heat, and then thethermoplastic polymer material transitions from the softened or liquidstate to the solid state when sufficiently cooled. As such,thermoplastic polymer materials are often used to join two objects orelements together. In this case, a yarn incorporating thermoplasticpolymer material may be utilized to join (a) the yarn to other portionsof the yarn, (b) the yarn to other yarns, (c) the yarn to inlaid strand132, or (d) knitted component 130 to skin layer 140, for example.

Inlaid strand 132, as noted above, extends through knit element 131 andpasses between the various loops within knit element 131. Moreparticularly, inlaid strand 132 is located within the knit structure ofknit element 131. Referring to FIGS. 7A and 7B, for example, knitelement 131 forms two separate and spaced textile layers, whicheffectively define a channel or tubular structure, and inlaid strand 132is located between the spaced textile layers. In some configurations,however, knit element 131 may have the configuration of a single textilelayer in the area of inlaid strand 132. In either configuration, inlaidstrand 132 is located within knit element 131 and between oppositesurfaces of knit element 131. Although inlaid strand 132 is primarilywithin knit element 131, portions of inlaid strand 132 may be visible orexposed on one or both surfaces of knit element 131.

When knitted component 130 is incorporated into footwear 100, inlaidstrand 132 extends in a generally vertical direction and from throatarea 124 to an area where sole structure 110 is secured to upper 120.More particularly, inlaid strand repeatedly passes through knit element131 from throat area 124 to an area adjacent to sole structure 110. Inthroat area 124, inlaid strand may also extend around lace-receivingelements 126, there by forming loops through which lace 125 passes. Incomparison with knit element 131, inlaid strand 132 may exhibit greaterstretch-resistance. That is, inlaid strand 132 may stretch less thanknit element 131. Given that numerous sections of inlaid strand 132extend toward sole structure 110 from throat area 124, inlaid strand 132imparts stretch-resistance to this area of upper 120. Moreover, placingtension upon lace 125 may impart tension to inlaid strand 132, therebyinducing the portion of upper 120 between throat area 124 and solestructure 110 to lay against the foot. As such, inlaid strand 132operates in connection with lace 122 to assist with securing upper 120around the foot and enhance the fit of footwear 100.

The configuration of inlaid strand 132 may vary significantly. Inaddition to yarn, inlaid strand 132 may have the configurations of afilament (e.g., a monofilament), thread, rope, webbing, cable, or chain,for example. In comparison with the yarns forming knit element 131, thethickness of inlaid strand 132 may be greater. In some configurations,inlaid strand 132 may have a significantly greater thickness than theyarns of knit element 131. Moreover, the materials forming inlaid strand132 may include any of the materials for the yarn within knit element131, such as cotton, elastane, polyester, rayon, wool, and nylon, butmay also include metals and a variety of engineering filaments that areutilized for high tensile strength applications, including glass,aramids (e.g., para-aramid and meta-aramid), ultra-high molecular weightpolyethylene, and liquid crystal polymer. As another example, a braidedpolyester thread may also be utilized as inlaid strand 132.

The combination of knitted component 130 and skin layer 140 providevarious advantages to footwear 100. In some configurations, however,skin layer 140 may be absent from footwear 100. That is, knittedcomponent 130 may be utilized individually to form portions of upper120, and knitted component 130 may form a majority of relatively largeportion of each of surfaces 121 and 122. Moreover, the presence ofprotruding areas 133 when skin layer 140 is absent may impart additionalthickness or loft to upper 120, while also varying the stretchproperties of upper 120. Although discussed in combination with skinlayer 140, therefore, knitted component 130 may be utilizedindividually.

Skin Layer Configuration

Skin layer 140 lays adjacent to knitted component 130 and is secured toknitted component 130 to form a portion of exterior surface 121. Asnoted above, skin layer 140 may be formed from a polymer sheet, elementsof leather or synthetic leather, a woven or non-woven textile, or ametal foil. When formed as a polymer sheet or polymer layer, skin layer140 may initially be a polymer film, polymer mesh, polymer powder, orpolymer resin, for example. With any of these structures, a variety ofpolymer materials may be utilized for skin layer 140, includingpolyurethane, polyester, polyester polyurethane, polyether polyurethane,and nylon. An example of a non-woven textile with thermoplastic polymerfilaments that may be bonded to knitted component 130 is disclosed inU.S. Patent Application Publication 2010/0199406 to Dua, et al., whichis incorporated herein by reference. Moreover, additional considerationsrelating to skin layer 140 may be found in U.S. Patent ApplicationPublication 2012/0246973 to Dua, which is incorporated herein byreference.

Although skin layer 140 may be formed from a thermoset polymer material,many configurations of skin layer 140 are formed from thermoplasticpolymer materials (e.g., thermoplastic polyurethane). In general, athermoplastic polymer material softens or melts when heated and returnsto a solid state when cooled. More particularly, the thermoplasticpolymer material transitions from a solid state to a softened or liquidstate when subjected to sufficient heat, and then the thermoplasticpolymer material transitions from the softened or liquid state to thesolid state when sufficiently cooled. As such, the thermoplastic polymermaterial may be melted, molded, cooled, re-melted, re-molded, and cooledagain through multiple cycles. Thermoplastic polymer materials may alsobe welded or thermal bonded to textile elements, such as knittedcomponent 130.

In many configurations of footwear 100, a single element of skin layer140 is secured throughout knitted component 130 and covers substantiallyall of knitted component 130. In further configurations, however,different elements of skin layer 140 may be formed from differentmaterials and positioned in separate areas of knitted component 130.That is, a portion of skin layer 140 formed from one material may bebonded to one area of knitted component 130, and another portion of skinlayer 140 formed from another material may be bonded to a different areaof knitted component 130. By varying the materials forming skin layer140, different properties may be applied to different areas of upper120. In other configurations, skin layer 140 may only cover specificareas of knitted component 130, thereby leaving other areas of knittedcomponent 130 exposed. Skin layer 140 may, therefore, be absent fromsome areas of knitted component 130.

Skin layer 140 is discussed above as being positioned on an exterior ofknitted component 130. In some configurations, however, skin layer 140may be bonded with an opposite surface of knitted component 130, therebyforming a portion of interior surface 122. In other configurations, twoskin layers 140 may be bonded to opposite surfaces of knitted component130, or skin layer 140 may impregnate or otherwise extend into knittedcomponent 130.

Protruding Areas

Knitted component 130 includes a plurality of protruding areas 133 thatextend outward and away from the void within upper 120. Protruding areas133 form bulges, protrusions, bumps, or other outwardly-extendingportions in knitted component 130. As with inlaid strand 132, many ofprotruding areas 133 extend in a generally vertical direction and fromthroat area 124 to the area where sole structure 110 is secured to upper120. Some of protruding areas 133 correspond with and incorporate inlaidstrand 132. In addition, some of protruding areas 133 extend in agenerally horizontal direction and between two other protruding areas133. That is, the horizontal protruding areas 133 extend between andeffectively join with two of the vertical protruding areas 133. Inaddition to providing a unique aesthetic to footwear 100, protrudingareas 133 may enhance the strength of upper 120 or impart a variety ofdifferent properties to upper 120.

Skin layer 140 extends over protruding areas 133 and may be secured toprotruding areas 133, as well as other areas of knitted component 130.As such, skin layer 140 forms corresponding bulges, protrusions, bumps,or other outwardly-extending portions at the locations of protrudingareas 133 and on exterior surface 121, as depicted in FIGS. 7A and 7C,for example. An advantage of this configuration is that the frictionproperties of footwear 100 may be controlled through the specificpattern that protruding areas 133 form in upper 120. As an example, thecombination of protruding areas 133 and skin layer 140 may provideenhanced control of a ball during the sport of soccer. That is, a soccerplayer may obtain enhanced control of a soccer ball through the raisedor outwardly-extending portions of upper 120 that are formed byprotruding areas 133.

Protruding areas 133 may be formed to have various configurations. Thatis, multiple knit structures and knitting techniques may be utilized toform protruding areas 133. As examples, each of FIGS. 8A and 8B depictan exemplary portion of upper 120 with two different configurations forprotruding areas 133. More particularly, a first of protruding areas 133includes a first tubular structure 134 and a portion of inlaid strand132, and a second of protruding areas 133 includes a second tubularstructure 135 and a plurality of yarn sections 136. Each of theseconfigurations will be discussed in more detail below.

First tubular structure 134 is an area of knit element 131 with twoseparate and spaced textile layers 137. Whereas edge areas of firsttubular structure 134 are joined and formed of unitary knitconstruction, a central area is unjoined and forms a channel in whichinlaid strand 132 is located. Although first tubular structure 134 aloneis sufficient to form one of protruding areas 133, the presence ofinlaid strand 131 provides additional thickness. Inlaid strand 132extends longitudinally and through first tubular structure 134, therebyextending along a length of first tubular structure 134.

Second tubular structure 135 is an area of knit element 131 with twoseparate and spaced textile layers 138, thereby having a configurationthat is similar to first tubular structure 134. Whereas edge areas ofsecond tubular structure 135 are joined and formed of unitary knitconstruction, a central area is unjoined and forms a channel in whichthe plurality of yarn sections 136 are located. Although second tubularstructure 135 alone is sufficient to form one of protruding areas 133,the presence of yarn sections 136 provides additional thickness.

Yarn sections 136 extend laterally and across second tubular structure135, thereby extending across a width of second tubular structure 135rather than along a longitudinal length of second tubular structure 135.Although the manner in which yarn sections 136 are secured may vary,yarn sections 136 are depicted as crossing each other in FIGS. 7A, 7C,8A, and 8B and may form tuck stitches on opposite sides of secondtubular structure 135. That is, tuck stitches may join yarn sections 136with opposite sides of second tubular structure 135. As depicted in abroken-away area of FIG. 8B, one of protruding areas 133 (i.e., ahorizontal protruding area 133) includes additional yarn sections 136and extends between and effectively joins tubular structures 134 and135, thereby extending from first tubular structure 134 to secondtubular structure 135. Although yarn sections 136 may cross each otherin extending across the width of second tubular structure 135, yarnsections 136 may have various other configurations. As examples, yarnsections 136 may lay in a plane and not cross each other, or yarnsections 136 may extend longitudinally and along a length of secondtubular structure 135.

As discussed above, protruding areas 133 form bulges, protrusions,bumps, or other outwardly-extending portions in knitted component 130.As such, protruding areas 133 are portions of knitted component 130 thathave greater thickness than other areas of knitted component 130. Inthis configuration, a majority or a relatively large portion of knittedcomponent 130 has a first thickness and the various protruding areas 133have a second thickness, with the first thickness being less than thesecond thickness. Depending upon the knit structures and knittingtechniques that are utilized to form knitted component 130, as well asthe yarns utilized in knitted component 130, the difference between thefirst thickness and the second thickness may range from one to tenmillimeters or more. In many configurations, the first thickness is lessthan four millimeters, and the second thickness is at least twomillimeters greater than the first thickness.

The specific pattern that protruding areas 133 form in upper 120 mayvary significantly. Referring to FIGS. 1 and 2, for example, protrudingareas 133 extend though a majority of lateral side 104 and medial side105, but are absent from a forward portion of forefoot region 101 and arear portion of heel region 103. The locations and configurations ofprotruding areas 133 may, however vary significantly. As an example,FIG. 9A depicts a configuration wherein the spacing between variousprotruding areas 133 varies throughout knitted component 130. Moreover,protruding areas 133 that extend between and connect other protrudingareas 133 are present in some areas, but absent in other areas. Althoughprotruding areas 133 are present in an area of knitted component 130that corresponds with forefoot region 101, protruding areas 133 areabsent in areas corresponding with heel region 103. In thisconfiguration, knit element 131 extends across a region correspondingwith throat area 124, thereby replacing tongue 127. FIG. 9B depictsanother configuration wherein protruding areas 133 are presentthroughout knitted component 130. Another configuration is depicted inFIG. 9C, wherein protruding areas 133 are located to correspond withinlaid strand 132, but are absent in other areas. In addition, in eachof the configurations depicted in FIGS. 9A-9C, portions of inlaid strand132 are exposed to form loops that receive lace 125. Accordingly,various aspects regarding knitted component 130 and protruding areas 133may vary considerably.

Bonding Process

A variety of processes may be utilized to join knitted component 130 andskin layer 140. In some configurations, skin layer 140 may be formedfrom a thermoplastic polymer material, which may be welded or thermalbonded to knitted component 130. As discussed above, a thermoplasticpolymer material melts when heated and returns to a solid state whencooled sufficiently. Based upon this property of thermoplastic polymermaterials, thermal bonding processes may be utilized to form a thermalbond that joins portions of skin layer 140 to knitted component 130. Asutilized herein, the term “thermal bonding” or variants thereof isdefined as a securing technique between two elements that involves asoftening or melting of a thermoplastic polymer material within at leastone of the elements such that the materials of the elements are securedto each other when cooled. Similarly, the term “thermal bond” orvariants thereof is defined as the bond, link, or structure that joinstwo elements through a process that involves a softening or melting of athermoplastic polymer material within at least one of the elements suchthat the materials of the elements are secured to each other whencooled. As examples, thermal bonding may involve (a) the melting orsoftening of skin layer 140 such that the thermoplastic polymer materialintermingles with materials of knitted component 130 and are securedtogether when cooled and (b) the melting or softening of skin layer 140such that the thermoplastic polymer material extends into or infiltratesthe structure of knitted component 130 (e.g., extends around or bondswith filaments or fibers in knitted component 130) to secure theelements together when cooled. Additionally, thermal bonding does notgenerally involve the use of stitching or adhesives, but involvesdirectly bonding elements to each other with heat. In some situations,however, stitching or adhesives may be utilized to supplement thethermal bond or the joining of elements through thermal bonding.

The bonding process utilizes a press 150, which includes a first pressportion 151 and a second press portion 152, as depicted in FIGS. 10A and11A. Each of press portions 151 and 152 have facing surfaces thatcompress knitted component 130 and skin layer 140 together. The surfacesof press portions 151 and 152 are substantially planar and includematerials with different compressibilities. More particularly, firstpress portion 151 includes a first material 153 and second press portion152 includes a second material 154. In comparison, first material 153has greater compressibility than second material 154. As examples ofsuitable materials, (a) first material 153 may be silicone and secondmaterial 154 may be steel, (b) both of materials 153 and 154 may besilicone, with first material 153 having greater thickness than secondmaterial 154, or (c) both of materials 153 and 154 may be silicone, withfirst material 153 having lesser density or hardness than secondmaterial 154. A variety of other materials may also be utilized,including various polymers and foams, such as ethylvinylacetate, andrubber. An advantage to silicone, however, relates to compression set.More particularly, silicone may go through numerous compressionoperations without forming indentations or other surface irregularities.

A process for bonding or otherwise joining knitted component 130 andskin layer 140 will now be discussed. In order to illustrate detailsassociated with the bonding process, the exemplary portions of knittedcomponent 130 and skin layer 140 that are depicted in FIGS. 8A and 8Bare utilized in FIGS. 10A-10D and 11A-11D. One skilled in this art willrecognize, however, that the concepts discussed herein and depicted inthe figures may be applied to the entirety of knitted component 130 andskin layer 140. Referring again to FIGS. 10A and 11A, skin layer 140 ispositioned adjacent to knitted component 130 and in an overlappingconfiguration. Whereas skin layer 140 is positioned adjacent to firstpress portion 151, knitted component 130 is positioned adjacent tosecond press portion 152. More particularly, skin layer 140 ispositioned to contact first material 153 (i.e., the more compressiblematerial), and knitted component 130 is positioned to contact secondmaterial 154 (i.e., the less compressible material). In order toproperly position knitted component 130 and skin layer 140, one or bothof (a) a jig that holds the components relative to each other and (b) ashuttle frame or other device that moves the components may be utilized.Additionally, a jig or other device may assist with ensuring thatknitted component 130 retains a proper shape and remains in a generallyplanar configuration during the bonding process.

Press 150 is utilized to compress knitted component 130 and skin layer140 together. In order to join knitted component 130 and skin layer 140,however, one or both of knitted component 130 and skin layer 140 areheated to a temperature that facilitates bonding. Various radiantheaters or other devices may be utilized to heat knitted component 130and skin layer 140 prior to placement between press portions 151 and152. In some manufacturing processes, however, press 150 may be heatedsuch that contact between press 150 and knitted component 130 and skinlayer 140 raises the temperature of the components to a level thatfacilitates bonding. Accordingly, the point at which one or both ofknitted component 130 and skin layer 140 are heated during this processmay vary.

Once knitted component 130 and skin layer 140 are positioned, pressportions 151 and 152 translate toward each other and begin to close uponthe components such that (a) the surface of first press portion 151having first material 153 begins to contact skin layer 140 and (b) thesurface of second press portion 152 having second material 154 begins tocontact knitted component 130, as depicted in FIGS. 10B and 11B. Pressportions 151 and 152 then translate further toward each other to fullycompress the components, as depicted in FIGS. 10C and 11C. At thisstage, skin layer 140 is effectively bonded or otherwise joined toknitted component 130. More particularly, the compressive force of press150, coupled with the elevated temperature of the compressed components,forms a thermal bond that joins knitted component 130 and skin layer140.

As noted above, first material 153 compresses more easily than secondmaterial 154. Referring to FIGS. 10C and 11C, areas of skin layer 140that are adjacent to protruding areas 133 press into first material 153,whereas second material 154 remains more planar, but compresses to alesser degree. Due to the different compressibilities between materials153 and 154, first material 153 compresses at the locations ofprotruding areas 133. Moreover, (a) portions of skin layer 140 that arein contact protruding areas 133 of knitted component 130 protrude intothe surface formed by first material 153 to a first depth and (b)portions of skin layer 140 that are in contact with other regions ofknitted component 130 (i.e., regions with lesser thickness) protrudeinto the surface formed by first material 153 to a second depth, thefirst depth being greater than the second depth. When bonding iscomplete, press 150 is opened and the bonded components are removed andpermitted to cool, as depicted in FIGS. 10D and 11D. As a final step inthe process, the combination of knit component 130 and skin layer 140may be incorporated into upper 120 of footwear 100.

The relative hardnesses, densities, and thicknesses between materials153 and 154 may vary considerably to provide different compressibilitiesbetween the surfaces of press 150. By varying the hardnesses, densities,and thicknesses, the compressibilities of the surfaces may be tailoredto specific pressing operations or configurations. While hardness,density, and thickness may each be considered, some configurations ofpress 150 may have materials 153 and 154 with only different hardnesses,only different densities, or only different thicknesses. Additionally,some configurations of press 150 may have materials 153 and 154 with (a)the same hardnesses and densities, but different thicknesses, (b) thesame hardnesses and thicknesses, but different densities, or (c) thesame densities and thicknesses, but different hardnesses. Accordingly,the various properties of materials 153 and 154 may be modified invarious ways to achieve different relative compressibilities between thesurfaces of press 150.

Each of materials 153 and 154 are depicted as having a substantiallyplanar surface. Depending upon the configuration of knitted component130 and the various protruding areas 133, however, the surfaces ofmaterials 153 and 154 may also be contoured. For example, first material153 may include various depressions or indentations that correspond withthe positions of protruding areas 133, thereby enhancing the degree towhich skin layer 140 wraps around protruding areas 133.

Press 150 provides one example of a device that may be utilized to bondknitted component 130 and skin layer 140. As another example, one ofpress portions 151 and 152 may be replaced with a flexible membrane anda pump may be utilized to evacuate air from between the membrane andsecond press portion 152. As the air is evacuated, the membrane willpress upon skin layer 140 and induce bonding. As another example, a dualmembrane system may be utilized to compress knitted component 130 andskin layer 140 together.

An advantage of selecting materials 153 and 154 to have differentcompressibilities relates to the three-dimensional aspect of upper 120that protruding areas 133 provide. More particularly, the differentcompressibilities ensures that protruding areas 133 continue to formbulges, protrusions, bumps, or other outwardly-extending portions whenknitted component 130 and skin layer 140 are compressed and bonded. Inthe absence of compressible materials, the degree to which upper 120includes outwardly-extending portions at protruding areas 133 may belessened.

Ankle Cuff Configuration

Another configuration of footwear 100 is depicted in FIGS. 12-15 asincluding an ankle cuff 160 for covering at least a portion of an ankleof the wearer. In addition to covering the foot, therefore, upper 120extends upward and covers a portion of the ankle. For referencepurposes, upper 120 may be divided into two general regions: a footregion 106 and an ankle region 107, as shown in FIGS. 12, 13, and 15.Foot region 106 extends through each of regions 101-103 and generallyencompasses portions of upper 120 corresponding with the foot. In manyconfigurations of footwear 100, foot region 106 corresponds withportions of upper 120 that are intended to be below the lateralmalleolus and the medial malleolus (i.e., the bony prominences on eachside of the ankle) of the wearer. Ankle region 107 is primarily locatedin heel region 103 and generally encompasses portions of upper 120corresponding with the ankle. In many configurations of footwear 100,ankle region 107 corresponds with portions of upper 120 that areintended to cover and extend above the lateral malleolus and the medialmalleolus.

Ankle cuff 160 is located in ankle region 107 and forms an ankle part ofknitted component 130. A remainder of knitted component 130, which islocated in foot region 106, forms a foot part of knitted component 130.Whereas the foot part of knitted component 130 covers the foot of thewearer, the ankle part of knitted component 130, which includes anklecuff 160, covers the ankle of the wearer when footwear 100 is worn.Moreover, ankle cuff 160 and the ankle part of knitted component 130 maybe formed of unitary knit construction with the foot part of knittedcomponent 130.

Although seam 129 may be present in ankle cuff 160, the ankle part ofknitted component 130 has a continuous structure for extending entirelyaround the ankle of the wearer. Referring to the top plan view of FIG.14, ankle cuff 160 forms a circular, oval, or otherwise continuous androunded opening 161 that provides access to the void within upper 120.Opening 161 may have relatively large dimensions that allow the foot topass through and into the void. In many configurations of footwear 100,however, opening 161 stretches to accommodate the foot. Moreover, anklecuff 160 may have dimensions that are less than an average ankle, andankle cuff may remain somewhat stretched and lay firmly against theankle once the foot is located within the void. Accordingly, ankle cuff160 and other portions of knitted component 130 in ankle region 107 maybe formed to have stretch properties.

Whereas ankle region 107 has stretch properties, foot region 108 ofupper 120 may stretch to a lesser degree to provide support for the footand limit movement of the foot relative to sole structure 120. That is,foot region 106 may have a first degree of stretch and ankle region 107may have a second degree of stretch, with the first degree of stretchbeing less than the second degree of stretch. In some configurations,portions of knitted component 130 in both of region 106 and 107 may havesimilar stretch properties, and the presence of inlaid strand 132 andskin layer 140 in foot region 106 may limit stretch in foot region 106.In other configurations, the ankle part of knitted component 130 may beformed from yarns or knit structures that impart stretch, whereas thefoot part of knitted component 130 may be formed from yarns or knitstructures that impart less stretch.

In order to enhance the stretch properties of ankle cuff 160, skin layer140 may be absent from ankle region 107. That is, skin layer 140 may beabsent from the ankle part of knitted component 130. In thisconfiguration, the ankle part of knitted component 130, including anklecuff 160, forms a portion of exterior surface 121 and interior surface122 in ankle region 107. As such, skin layer 140 and the portionsknitted component 130 that form ankle cuff 160 form a majority ofexterior surface 121, and knitted component 130 alone may form arelatively large portion of interior surface 122.

In the area of ankle cuff 160, skin layer 140 forms a concave edge 141that extends downward on each of sides 104 and 105. More particularly,skin layer 140 may be absent from areas of knitted component 130 thatcover the lateral malleolus and the medial malleolus. An advantage ofthis configuration is that ankle cuff 160 may stretch over the lateralmalleolus and the medial malleolus, thereby enhancing the comfort offootwear 100. In other configurations, skin layer 140 may extend upwardto cover the lateral malleolus and the medial malleolus, or edge 141 maybe relatively straight or convex in the area of ankle cuff 160.

Based upon the above discussion, ankle cuff 160 may exhibit greaterstretch than other portions of upper 120. In addition to allowing thefoot to enter footwear 100, this structure provides support for the footand limits movement of the foot relative to sole structure 120. Inaddition, ankle cuff 160 may remain in a stretched state and lay againstthe ankle when footwear 100 is worn, which imparts two advantages:First, ankle cuff 160 prevents or limits dirt, dust, and other debrisfrom entering footwear 100. Second, the wearer may sense the presence ofankle cuff 160 around the ankle, which enhances the wearer'sproprioceptive awareness of the foot.

Lace Channel Configuration

A further configuration of footwear 100 is depicted in FIGS. 16 and 17as including various lace channels 170 in tongue 127. Lace 125 passesthrough lace channels 170, thereby locating portions of lace 125 withintongue 127. Referring to FIGS. 18 and 19, which depict tongue 127separate from a remainder of footwear 100, each of lace channels 170 areoriented diagonally with respect to a longitudinal axis of footwear 100.The locations of lace channels 170 generally correspond with thelocations of lace-receiving elements 126 and follow the natural path oflace 125 as it passes between lace-receiving elements 126. That is, thepositions and orientations of lace channels 170 are selected such thattwo of lace-receiving elements 126 are located adjacent to opposite endsof each lace channel 170. In effect, therefore, lace channels 170 arelocated along a line that extends between two lace-receiving elements126. Moreover, lace 125 extends through the various lace channels 170and engages lace-receiving elements 126 that are located on oppositesides of lace channels 170. As such, lace 125 follows a zigzagging pathbetween lace-receiving elements 126.

Lace channels 170 have a structure that is similar to tubular structures134 and 135. As such, lace channels 170 include two separate and spacedtextile layers 171 that overlap each other. Whereas edge areas of lacechannels 170 are joined and formed of unitary knit construction, acentral area is unjoined and forms a tubular structure in which lace 125is located. That is, lace 125 extends longitudinally and through eachlace channel 170, thereby extending along a length of each lace channel170.

Although various methods may be utilized to form tongue 127, a knittingprocess (e.g., flat knitting process) may be utilized. In configurationswhere a similar knitting process is utilized for tongue 127 and knittedcomponent 130, each of tongue 127 and knitted component 130 may havesimilar properties, materials, and aesthetics. Additionally, anadvantage of the knitting process is that lace channels 170 may beformed of unitary knit construction with a remainder of tongue 127,which provides efficient manufacture and imparts a smooth and seamlessconfiguration to tongue 127.

A configuration of knitted component 130 in combination with lace 125 isdepicted in FIG. 20. As with the configurations in FIGS. 9A-9C, knitelement 131 extends across a region corresponding with throat area 124,thereby replacing tongue 127. Moreover, knit element 131 forms thevarious lace channels 170. As with the various lace channels 170 intongue 127, lace channels 170 in this configuration are two separate andspaced textile layers that overlap each other, are formed of unitaryknit construction, and receive lace 125.

Lace 125 is depicted as extending through lace channels 170 in FIG. 20.In place of apertures that form lace-receiving elements 126, inlaidstrand 132 is exposed and forms loops for receiving lace 125. That is,the loops formed by inlaid strand 132 are lace-receiving elements 126,which are located on opposite sides of throat area 124. Lace 125 extendsthrough (a) the loops formed by inlaid strand 132 and (b) the variouslace channels 170. As with tongue 127, each of lace channels 170 areoriented diagonally with respect to a longitudinal axis and follow thenatural path of lace 125. That is, the positions and orientations oflace channels 170 are selected such that two loops are located adjacentto opposite ends of each lace channel 170. As such, lace 125 follows azigzagging path between the loops formed by inlaid strand 132.

Lace channels 170 may have various lengths. In FIG. 16, ends of lacechannels 170 are positioned adjacent to an edge of knitted component 130in throat area 124. Although knitted component 130 overlaps portions oftongue 127, ends of lace channels 170 are exposed and receive lace 125.In FIG. 20, ends of lace channels 170 are positioned adjacent to theloops that form lace-receiving elements 126. In either configuration,one or more of lace channels 170 may have a length greater than threecentimeters. In other configurations, however, lace channels 170 mayrange from one to more than ten centimeters.

A further configuration of knitted component 130 is depicted in FIGS. 21and 22 as defining various apertures 172 between loops formed by inlaidstrand 132 and in the region corresponding with throat area 124.Apertures 172 form openings that extend through knit element 131. Inthis configuration, lace 125 extends through the various apertures 172,and portions of lace 125 are located adjacent to an opposite side ofknit element 131. More particularly, lace 125 passes through the loopsformed by inlaid strand 132 and enters apertures 172, therebypositioning portions of lace 125 that are between the loops adjacent tothe opposite side of knit element 131. The locations of apertures 172generally correspond with the locations of the loops formed by inlaidstrand 132 and follow the natural path of lace 125. That is, apertures172 are located along a line that extends between two of the loopsformed by inlaid strand 132.

Further Configurations

Various configurations of footwear 100, upper 120, knitted component130, and skin layer 140 are discussed above. There configurations,however, are intended to provide examples of structures and otherfeatures that may be incorporated into footwear 100. Although manyvariations upon footwear 100, upper 120, knitted component 130, and skinlayer 140 are possible, some additional configurations are discussedbelow.

In many configurations of footwear 100, knitted component 130 forms amajority of interior surface 122. Referring to FIGS. 23 and 24, aninterior layer 180 is depicted as being secured to knitted component 130and forming a portion of interior surface 122. Interior layer 180 mayinhibit stretch in upper 120 and may enhance the wear-resistance orabrasion-resistance of upper 120.

Interior layer 180 may also impart water-resistance to footwear 100.Additionally, forming footwear 100 to include interior layer 180 mayprovide uniform fit and conformance to the foot, a relatively seamlessinterior with enhanced comfort for the wearer, a relatively lightweight, and support for the foot. Although interior layer 180 may beutilized in configurations that also include skin layer 140, interiorlayer 180 may be utilized in the absence of skin layer 140 or as areplacement for skin layer 180.

Interior layer 180 may extend over substantially all of knittedcomponent 130 or may be absent in specific areas of knitted component130. In areas corresponding with forefoot region 101, for example,interior layer 180 defines a plurality of apertures 181 that may enhancethe stretch, flex, and breathability properties of upper 120. By varyingthe size, position, and number of apertures 181, the properties of upper120 may also be varied. In areas adjacent to inlaid strand 132, interiorlayer 180 is formed to define larger apertures and has an articulatedstructure, which may promote flex in areas corresponding with midfootregion 102, while also providing stability and stretch-resistance. Thisportion of interior layer 180 may also experience tension and resiststretching when lace 125 is tightened. As such, the combination ofinterior layer 180 and inlaid strand 132 may impart greater resistanceto stretch in upper 120. In areas corresponding with heel region 103,interior layer 180 is located to provide additional stretch-resistanceand durability to collar 123. It should also be noted that interiorlayer 180 extends to edges of knitted component 130 that are joined withstrobel sock 128, which effectively ties or joins interior layer 180 tosole structure 110.

Various materials may be utilized for interior layer 180. As an example,interior layer 180 may be a polymer layer with many of the properties ofskin layer 140. Interior layer 180 may also be a textile, such as amicrofiber textile, that is adhered or bonded to knitted component 130.In some configurations, interior layer 180 may have a layeredconfiguration that includes a thermoplastic polymer material for thermalbonding with knitted component 130.

Although skin layer 140 may cover substantially all of knitted component130, skin layer 140 may be absent from some areas of knitted component130. With reference to examples discussed above, skin layer 140 may beabsent from throat area 124 or ankle region 107. As another example,FIG. 25A depicts skin layer 140 as being present in areas correspondingwith midfoot region 103 and areas that include inlaid strand 132, butabsent in areas corresponding with forefoot region 101 and heel region103. Moreover, skin layer 140 covers some of protruding areas 133, butleaves other protruding areas 133 exposed. Accordingly, skin layer 140may only cover specific areas of knitted component 130, thereby leavingother areas of knitted component 130 exposed.

A single element of skin layer 140 is secured to knitted component 130in many configurations discussed above. Referring to FIG. 25B, a partingline 142 extends longitudinally through an area corresponding withforefoot region 101, thereby separating different sections of skin layer140. In this configuration, each section of skin layer 140 may havedifferent properties. More particularly, the material forming skin layer140, the thickness of the material, or other properties may vary betweenthe sections of skin layer 140, thereby imparting different propertiesto different areas of upper 120. In further configurations, parting line142 may be located in other areas, or the sections of skin layer 140 maybe spaced from each other to expose a portion of knitted component 130.

The invention is disclosed above and in the accompanying figures withreference to a variety of configurations. The purpose served by thedisclosure, however, is to provide an example of the various featuresand concepts related to the invention, not to limit the scope of theinvention. One skilled in the relevant art will recognize that numerousvariations and modifications may be made to the configurations describedabove without departing from the scope of the present invention, asdefined by the appended claims.

What is claimed is:
 1. A method for manufacturing an upper for anarticle of footwear, the method comprising: positioning a skin layeradjacent to a knitted component and in an overlapping configuration, theknitted component having regions with different thicknesses; locatingthe skin layer and the knitted component between a first surface and asecond surface of a press, the first surface including a first material,and the second surface including a second material, the first materialhaving greater compressibility than the second material; and compressingthe skin layer and the knitted component between the first surface andthe second surface to join the skin layer to the knitted component. 2.The method recited in claim 1, wherein the step of locating includesselecting (a) the first material have a first hardness and (b) thesecond material to have a second hardness, the first hardness being lessthan the second hardness.
 3. The method recited in claim 1, wherein thestep of locating includes selecting (a) the first material have a firstthickness and (b) the second material to have a second thickness, thefirst thickness being greater than the second thickness.
 4. The methodrecited in claim 1, wherein the step of locating includes selecting thefirst material to be silicone.
 5. The method recited in claim 1, whereinthe step of locating includes selecting each of the first material andthe second material to be silicone.
 6. The method recited in claim 1,further including a step of heating the skin layer and the knittedcomponent.
 7. The method recited in claim 1, further including a step ofincorporating the skin layer and the knitted component into the upper ofthe article of footwear following the step of compressing.
 8. The methodrecited in claim 7, wherein the step of incorporating includespositioning the skin layer to form a portion of an exterior surface ofthe article of footwear.
 9. The method recited in claim 1, furtherincluding a step of selecting the skin layer to include a thermoplasticpolymer material.
 10. A method of manufacturing an element, the methodcomprising: positioning a skin layer adjacent to a knitted component andin an overlapping configuration, the knitted component having a firstregion and a second region, the first region having greater thicknessthan the second region; locating the skin layer and the knittedcomponent between a first surface and a second surface of a press, theskin layer being located adjacent to the first surface, and the knittedcomponent being located adjacent to the second surface, the firstsurface including a first material, and the second surface including asecond material, the first material having greater compressibility thanthe second material, and each of the first surface and the secondsurface having a substantially planar configuration; heating the skinlayer and the knitted component; and compressing the skin layer and theknitted component between the first surface and the second surface suchthat (a) portions of the skin layer that are in contact with the firstregion of the knitted component protrude into the first surface to afirst depth and (b) portions of the skin layer that are in contact withthe second region of the knitted component protrude into the firstsurface to a second depth, the first depth being greater than the seconddepth.
 11. The method recited in claim 10, wherein the step of locatingincludes selecting (a) the first material have a first hardness and (b)the second material to have a second hardness, the first hardness beingless than the second hardness.
 12. The method recited in claim 10,wherein the step of locating includes selecting (a) the first materialhave a first thickness and (b) the second material to have a secondthickness, the first thickness being greater than the second thickness.13. The method recited in claim 10, wherein the step of locatingincludes selecting the first material to be silicone.
 14. The methodrecited in claim 10, wherein the step of locating includes selectingeach of the first material and the second material to be silicone. 15.The method recited in claim 10, further including a step ofincorporating the skin layer and the knitted component into an articleof footwear following the step of compressing.
 16. The method recited inclaim 15, wherein the step of incorporating includes positioning theskin layer to form a portion of an exterior surface of the article offootwear.
 17. The method recited in claim 10, further including a stepof selecting the skin layer to include a thermoplastic polymer material.